High Performance Horizontal Machining Center

The HP 4000/5100 meets all of today's market needs for high precision

in the high-speed continuous machining, a wide range of

automation application and machining of any material, space saving,

easy chip removal with advanced technology.

High productivity reliable

horizontal machining center

2

High Speed Spindle

2222 kkWW1144000000 rr//mmiinn{opt : 20000 r/min}

MMaaxx.. ssppiinnddllee ssppeeeedd MMoottoorr ((3300mmiinn))

● Standard 14000 r/min (18.5/22kW)

■Spindle power-torque diagram

● Option 20000 r/min (15/18.5kW)

The high speed 14000 r/min 40 taper spindle is a true cartridge type unitsupported by four precision class high speed bearings which arepermanently greased and lubricated. The spindle is driven by a hightorque 22 kW A.C. motor delivering an impressive 220.5 N.m.

High speed and precision with advanced technology

SPINDLE SPEED (r/min)

POWER (kW)TORQUE (N.m)

18.5S2(10min.)

S1(Cont.)

S1(C

ont.)

2000010000600040002000

9.69

6.53

1.73

1.43

15

10

2.45

1.63

1500

0.90.81

S2(1

0min

)

S2(10min.)

S1(Cont.)

TORQUE (N.m)

SPINDLE SPEED (r/min)

POWER (kW)

1.201.52

16.3219.4922.55

14000

S1(Cont.)

S2(30min.)18.522.0

26001100950

0

S2(15min.)S1(Cont.)

S3(25%ED)

S3(25%

ED)

S1(Con

t.)

S2(15m

in.)

8.256.94

4

OOiill ccoooolleerr

DDuuaall ccoonnttaacctt ssyysstteemm ((BBiigg pplluuss::SSttdd..)) HHSSKK SSppiinnddllee ((OOpptt..))

TTooooll ccllaammppiinngg ffoorrccee

The refrigerated cooling system maintains auniform spindle temperature required forhigh accuracy and extended production.Thermo sensors regulate the temperature ofthe oil which is circulated through oiljackets around the spindle, as well as thedrive shaft bearings, gears, and motorflanges.

1100000000NN

The HSK shank system with two restrained faces simultaneouslycouples the taper portion of the shank and the flange end face.The hollow 1/10 taper changes flexibly while the flange end facefit tightly to the spindle nose.

Variable Spindle

The dual contact system offers simultaneous dual contactbetween the machine spindle face and toolholder flange face, aswell as the machine spindle taper and long toolholder tapershank. This system is based on the most currently availablestandards for BT, DIN and CAT flange tooling.

■Higher rigidity

■Improved ATC repeatability, surface finish and higher precision machine

■Extended tool life

Dual contact faces

P

T

OJP OJT

M

OIL COOLER

■Improved high speed and heavy duty cutting performance

■Improved machining accuracy

5

4400 ttoooollss {{OOpptt :: 6600//112200//117700}}

TTooooll ssttoorraaggee ccaappaacciittyy

The ATC is composed of tool magazine andchange arm. The tools are selected by a fixedaddress method that follows the shorter path. Alltools are returned to the pots from which theywere originally taken so that collision problemsinvolving large-sized tools need to be consideredonly once when they are first mounted.

11..00 ss ((TT--TT--TT))

TTooooll cchhaannggee ttiimmee

Sophisticated mechanisms drasticallyreduce non-cutting time.

AAuuttoommaattiicc ttooooll cchhaannggeerr

D m

m

L mm

MMaaxxiimmuumm ttooooll ssiizzee

Tool Magazine

ØØ7755 mmmm ((CCoonnttiinnuuoouuss))

ØØ114400 mmmm ((AAddjjaacceenntt ppoorrttss aarree eemmppttyy))

Max. tool diameter

333300 mmmm ((HHPP 44000000))440000 mmmm ((HHPP 55110000))

Max. tool length

1100 kkggMax. tool weight

6

11..44 ss ((00 9900。。))

11。。Minimum table indexing angle

Table indexing time

TTaabbllee

The possibility that chips might degrade the meshing accuracy of the palletpositioning mechanism increases at higher machining speeds. On the HP5100 strong jets of air are discharged from the tapered cones when a pallet ischanged to clean any chips from the cones and assure accurate palletpositioning.

Automatic Pallet Changer

D mm

W kg

H m

m

HHPP 44000000 HHPP 55110000

PPaalllleett ssiizzee 400×400mm 500×500mm

MMaaxx..wwoorrkkppiieeccee ssiizzee Ø600×H 800mm Ø800×H 930mm

MMaaxx..wwoorrkkppiieeccee wweeiigghhtt 400 kg 500 kg

MMaaxx.. WWoorrkkppiieeccee SSiizzee..

HP 4000/5100 are equipped with rotary shuttle type APC(Automatic PalletChanger) as a standard feature. It provides high reliability and wide workingarea for easy setup. The pallet changer is rigidly built and operates with theopening and closing of the splash guard to accomplish pallet changes in 7.0seconds.

Pallet change time

7

77..00 ss ((HHPP 44000000)) // 77..55 ss ((HHPP 55110000))

Rigid Structure Bed and Column

FFEEMM aannaallyyssiissThe machine is designed to build rigidity into a stable body.The construction of the machine was thoroughly examinedfrom the stage of basic design to ensure consistent high-speedand high-accuracy operation. The deformation of the bedwhen subject to a load at the center was simulated to securehigh level rigidity against bending. The HP 4000/5100 has andesign with a basic structure using FEM advanced technology.

TTrraavveell aaxxeess ((XX//YY//ZZ))

HP 4000

8

660000//556600//660000 mmmm

HP 5000

885500//770000//775500 mmmm

The feed mechanism adopts heavy duty linearmotion roller guideways that provide superioracceleration/deceleration performance to reducenon-cutting time.

BBaallll ssccrreeww nnuutt wwiitthhccoooolliinngg jjaacckkeett ((ssttdd..)) OOiill CCoooolleerr

BBaallll ssccrreeww sshhaaffttccoooolliinngg ((oopptt..))

Machine units are designed minimum thermal transformation by ball screwnut with cooling jacket and ball screw shaft cooling (option) and ‘DBD’ type3-bearings support high accuracy.

Rapid traverse

Minimum thermal transformation for high accuracy

Interface for Fixture

FFiixxttuurree cchheecckk lliisstt (for hydraulic/pneumatic fixtures)

NNuummbbeerr ooff PPoorrttss

2*1×2*2 Line

2*1×3*2 Line

2*1×4*2 Line

2*1×6*2 Line

2*1×8*2 Line

*1 : Pallet No. 1 and No. 2(Number of Pallet)

*2 : Number of port line

HHyyddrraauulliicc ppoowweerr uunniitt

Special requirement

L/min at MPa

Contact Doosan for more information

Guideways and Axis Drives

9

6600 mm//mmiinn

Ergonomic and Eco-Friendly Design EEaassyy sseettuupp

Less waste lubrication oil extends the life time ofthe coolant water and cut down the grime andoffensive smell of the machine inside.

CCoolllleeccttiioonn ooff wwaassttee lluubbrriiccaattiioonn ooiill

Rigorously designed, manufactured and testedmachine covers do not permit coolant leakage inany condition. The factory always keeps ourenvironment clean.

NNoo ccoooollaanntt lleeaakkaaggee

OOiill sskkiimmmmeerr ((oopptt..))

Another suggestion to prolongthe life time of the coolantwater. A belt-driven type oilskimmer picks up and removeswaste oil from the coolant tankthat is easily drained.SSwwiivveelllliinngg

ooppeerraattoorr′′ss ppaanneell

550000 mmmm

11114400 mmmm

Distance to table

Height to table

10

PPoorrttaabbllee MMPPGGkkeeeeppiinngg ssppaaccee

TThhrroouugghh--ssppiinnddllee ccoooollaanntt ssyysstteemm OOiill mmiisstt ccoolllleeccttoorr MMiinniimmuumm QQuuaannttiittyy LLuubblliiccaattiioonn

SShhoowweerr ccoooollaanntt FFlloooodd ccoooollaanntt CCoooollaanntt gguunn

Air+Oil mist

Coolant System

XX--aaxxiiss ((HHPP 44000000 oonnllyy))

Improved Units for Maintenance

DDoouubbllee FFiilltteerriinngg AAiirr SSeerrvvee UUnniitt

Double filtering air service unit is centralizedposition in the machine for easy main-tenance

LLaarrggeesstt LLuubbrriiccaattiioonn PPuummpp && TTaannkk

The large capacity lubrication tank willsupport for silky and stable moving of eachunits.

OOnnee SStteepp SSlliiddee CCoovveerr

The one step slide cover will prevent that units are damaged byminute chip penetration

Misting device

11

Chip Disposal

Hinge type Scraper type Drum filter type

Separate chip conveyor and coolant tank provide easycleaning and maintenance. A telescopic cover, inclined at a250。angle, directs chips into the coil type chip conveyor tokeep the area around the table clean.

From the sliding cover, chips are flushed onto the chipconveyor by the coil screw conveyors to make quick andeasy work of chip removal. The chip conveyor mounting isavailable for rear and side type.

Improved chip disposal

12

Chip conveyor (Option)

×○○

○×○

×△○

×○○

• ○:Available ×:Unavailable △:Asking for information• Some types of chips may not be completely removed from the chip conveyor.• Contact Doosan for more information.

Steel Cast Aluminum andnonferrous metals

Specifications

Compound

Hinge type

Scraper type

Drum filter type

FFaaccee mmiillll Carbon steel (SM45C)

Ø80 Face mill (6Z)

DDrriillll Carbon steel (SM45C)

Ø49 Drill (2Z)

TTaapp Carbon steel (SM45C)

Ø38.5 Drill

68mm

3mm49mm

68mm

3mm

100mm

3mm60mm

68mm

3mm49mm49mm

100mm

3mm60mm

68mm

3mm49mm

100mm

3mm60mm

FFaaccee mmiillll Aluminum

Ø100 Face mill (7Z)

DDrriillll Carbon steel (GC25)

Ø49 Drill (2Z)

TTaapp Carbon steel (GC25)

68mm

3mm49mm

100mm

3mm60mm

100mm

3mm

68mm

3mm49mm

100mm

3mm60mm60mm

68mm

3mm49mm

100mm

3mm60mm

Machining rate

Spindle speed Feedrate

Machining rate


Tool


Cutting Performance

13

8855 cm3/min

116600 rr//mmiinn 4455 mmmm//mmiinn

771144 cm3/min


MM4422××PP44..55112200 rr//mmiinn 554400 mmmm//mmiinn

Machining rate


Machining rate


Tool


330000 cm3/min


33112200 cm3/min


MM4422××PP44..55220000 rr//mmiinn 11220000 mmmm//mmiinn

11500

8500

HHPP 55110000

Flexible Multi Pallet SystemTTooooll mmaaggaazziinnee

Numerous Variations to meet production efficiency needs.

HHPP 55110000

unit : mm

Application technology of Multi-pallet system

is the best solution for the high productivity

in the machining shop.

AApppplliiccaattiioonn ooff mmuullttii ppaalllleett ssyysstteemm

Name HP 5100 (2 sets)

Number of Setup Station 1Storage Capacity (500×500) 18 cells

■ 7-Station Round Type Multi Pallet Magazine

■High Productivity & availability■Flexible production solutions■High efficiency system■Compact designed technology■Easy to extend stations

(HP 4000/5100 : 7, 9, 11, 13st)

14

60-tool (opt.)

120-tool (opt.)

170-tool (opt.)

Sample Workpiece

X-frame Inboard door Ring-rib Water pump cover

Control valve Front cover Brake caliper Casting

Control valve Pump body Cylinder/Crank case Grip arm

15

Standard Features

Flood coolant Operator call lamp (red/yellow/green)

FANUC 18i-MB controller Portable MPG

Work light APC operator's panel

Rigid tapping Oil cooler

Screw conveyor

16

Multi pallet system 120 Tools Matrix magazine (170 Tools)

Linear scale feedback system Automatic measuring systemAutomatic tool length measurement with senser

Built in Rotary Table (0.001。) FMS Through the spindle coolant

Chip conveyor / Bucket T-slot pallet Shower coolant

• Air gun

• Automatic power off

• Center bush

• Coolant chiller

• Coolant gun

•Hyd. cooling / Heating device

•Hydraulic line for fixture

•HSK tooling

• Rear type chip conveyor

• Test bar

Optional Equipment

17

■High compact CNC is realized through LCD display with integrated CNC and a flash memory card interface is standard features.■Provides many support functions for set-ups, such as tool measurement, workpiece measurement at the original point, and workpiece

measurement inside the machine.■Uses one display screen to perform all operations including programming,

checking by animation, and real machining.■User-Friendly Operation : Soft key Selection of Comprehensive Cycle Library

SSttaannddaarrdd FFeeaattuurreess

Easy Operating System

Guide for machining preparationIn preparation for machining, simple instructionson a selected screen allow to measure the settingerror of workpiece and tool offset value forautomated adjustment.

18

Tool Monitoring System (Opt.)

■For machining center, turning center and compound machine with millingand turning.

■Solid modeling provides high speed animation. (TFT-LCD Color Only)

■Icon menu soft-keys provide convenient programming for sophisticated milling and turning.

■Measurement cycles provide automatic offset measurement of workpiece (Available for machining center and for compound machine).

■Registration of parameter sets for high speed machining and/or for highprecision machining with machine configurations.

■Instruction of precision level for desired machining selects appropriate

parameters automatically.

■Precision level can be instructed through NC program.

Easy operation system

One single screen provides handy operation guidancefor programming through machine operation.

One single screen provides convenient operation &parameter setting for high speed and high precisionmachining instructions.

Machining condition selecting function

TTooooll llooaadd mmoonniittoorriinngg ssyysstteemm TTooooll mmaannaaggeemmeenntt ffuunnccttiioonnTool Monitoring System is one of safety

functions to protect Tool and Spindle against

a possible damage of abnoraml load caused

by tool wear and breakage or others. This

system montitors the tool status during

machine operation by detecting the abnormal

load of exch axis and spindle.

•The screen shows a tool and pallet No.,

load meter of each axis and spindle limit

load.

•This functions consisted of tool pre-check

function, substitutive tool selection with

tool life management and different tool &

port number command function.

19

SIDE TYPE CHIP CONVEYOR

4587

5827

1624

615

547

389

630

2552

982

4164

610 630

1457

1130

2772

(60

TO

OL)

1280

240

820

317

2,34

0

2340

494

2873

OIL COOLER

630R

630

R

600R

815

2795

630

4240

75 4928 4305433

236

2024

535

600

2763

OILCOOLER

254030

24 700

ST

.

unit : mm

External Dimensions

20

Front View Side View

Top View

Front View Side View

Top View

unit : mm

unit : mm

Pallet Dimensions

Tool Shank

MAS403 BT40 DIN40

CAT40Nikken PS806

22.8 25

16.1

ø63.

55ø5

6.25

7.07

11.1

ø44.

45

"T"7/24 TAPER

TAPER GAGE LINE

60˚

ø17

ø23

"T" 15˚

ø14

28 26

ø17 20

42

ø1930˚

68.43515.92 3.18

ø7 H

OLE

ø44.

7

15˚

TAPER GAGE LINE

ø17

ø14

ø19

ø44.

45

ø63.

55ø5

0

ø17

11.1

15.9 3.2 68.4

35

M16xP2.022.825

204

2

ø23 30˚

ø7 H

OLE

7/24 TAPER

M16xP2.0

ø7

ø72.

3

ø75.

68

44.4

5

16.6

25 65.4

ø23

ø19

ø17

ø14

15˚

30˚

M16xP2.0

23

25 29 4

2

2

60˚ø10

TAPER GAGE LINE

7/24 TAPER

M16x2.0 TAP

ø17H

7

ø19

ø63

ø53

16.118

.5

18.5

2628

60˚

HOLE FOR M1655 55

40

400

40 4080

8080

8040

400

25

1836

80 80 80 80

24-M16X2 TAP,DP30

HOLE FOR M16

5010010010010050

24-M16X2 TAP,DP30

36

18

25

7575

500

500

5010

010

010

010

050

21

■Assembly & Operation tools

■Coolant tank flood coolant & cleaning Flushing

■Door interlock for safety

■FANUC 18i-MB controller

■Full enclosure spash guard

■Installation parts

■Operator call lamp (red, yellow, green)

■Rigid tapping

■Screw conveyor

■Spindle Cooling unit & oil cooler

■Work light

·Design and specifications are subject to change without notice.·Doosan is not responsible for difference between the information in the catalogue and the actual machine.

Machine Specifications

Note : { } are optional

Descriptions HP 4000 HP 5100X-axis mm 600 850

Y-axis mm 560 700

Z-axis mm 600 750

Distance from spdl center to pallet top mm 50~610 50~750

Distance from spdl nose to table center mm 150~750 150~900

Pallet size mm 400×400 500×500

Pallet loading capacity kg 400 500

Pallet surface 24-M16×P2.0

Pallet index degree deg 1{0.001}

Max. spindle speed r/min 14000{20000}

Spindle taper ISO#40, 7/24Taper

Max. spindle torque (25% ED) N.m 220.5

Rapid traverse rate(X/Y/Z) m/min 60

Cutting feedrate mm/min 30000

Type of tool shank MAS403 BT40

Tool storage capacity 40{60/120/170}

Max. tool diameter mm ø75

Max. tool diameter without adjacent tools mm ø140

Max. tool length mm 330 400

Max. tool weight kg 10

Method of tool selection Fixed address

Tool change time(tool-to-tool) s 1.0

Tool change time(chip-to-chip) s 3.5

Number of pallet ea 2 2{7/9/11/13}

Type Rotary shuttle

Pallet change time s 7.0 7.5

Pallet rotation in loading station deg 90

Spindle motor (30 min) kW 18.5/22

Feed motor(X/Y/Z/B) kW 7.0/7.0/7.0/2.7

Electric power supply (Rated capacity) kVA 65

Compressed air supply Mpa 0.54

Coolant tank capacity L 640

Lubrication tank capacity L 4.3

Machine height mm 2880 3030

Machine dimension mm 5400×2560 5600×2800

Machine weight kg 14000 15000

Travel

Table

Spindle

Feedrate

Automatic

tool changer

Automatic

pallet changer

Motor

Machine size

Tank capacity

Power source

Standard Feature

22

- Program number O4-digits- Program protect- Program stop / end M00 / M02,M30- Programmable data input Tool offset and work offset are entered by G10, G11- Sub program Up to 4 nesting- Tape code ISO / EIA Automatic discrimination- Work coordinate system G54 - G59- Additional work coordinate system(48 Pair) G54.1 P1 - 48 pairs- Coordinate system rotation G68, G69- Extended part program editing- Optional angle chamfering / corner R- Macro executor

OOTTHHEERRSS FFUUNNCCTTIIOONNSS ((OOppeerraattiioonn,, SSeettttiinngg && DDiissppllaayy,, eettcc))- Alarm display- Alarm history display- Clock function- Cycle start / Feed hold- Display of PMC alarm message Message display when PMC alarm occurred- Dry run- Ethernet function(Embeded)- Graphic display Tool path drawing- Help function- Loadmeter display- MDI / DISPLAY unit 10.4 color LCD, Keyboard for data input, soft-keys- Memory card interface- Operation functions Tape / Memory / MDI / Manual- Operation history display- Program restart- Run hour and part number display- Search function Sequence NO. / Program NO.- Self - diagnostic function- Servo setting screen- Single block- External data input- Multi language display

OOPPTTIIOONNAALL SSPPEECCIIFFIICCAATTIIOONNSS- 3-dimensional coordinate conversion- 3-dimensional tool compensation- 3rd / 4th reference return standard only for HM 1000- Addition of tool pairs for tool life management 512 pairs- Additional controlled axes max. 6 axes in total- Additional work coordinate system G54.1 P1 - 300 (300 pairs )- AI HPCC* (High Precision Contour Control) with 64 bit Risc 600 block preview- Automatic corner override G62- Chopping function G81.1- Cylindrical interpolation G07.1- Data server- Dynamic graphic display Machining profile drawing- Exponential interpolation- Interpolation type pitch error compensation- EZ Guide i (Doosan infracore Conversational Programming Solution) with 10.4 Color TFT- Tape format for FS15 - Increment system 1/10- Figure copying G72.1, G72.2- Manual handle feed 2/3 unit- Handle interruption- High speed skip function- Involute interpolation G02.2, G03.2- Look ahead control G08- Machining time stamp function- No. of Registered programs 400 / 1000 ea- Number of tool offsets 400 / 499 / 999 ea- Optional block skip addition 9 blocks- Part program storage 1280 / 2560 m- Playback function- Polar coordinate command G15 / G16- Polar coordinate interpolation G12.1 / G13.1- Programmable mirror image G50.1 / G51.1- Remote buffer- Scaling G50, G51- Single direction positioning G60- Stored stroke check 2 / 3- Tool load monitoring function(doosan)- Doosan tool management package Ⅰ- Tool position offset G45 - G48- Position switch

AAXXEESS CCOONNTTRROOLL- Controlled axes 4 (X,Y,Z,B)- Simultaneously controllable axes

Positioning(G00)/Linear interpolation(G01) : 3 axesCircular interpolation(G02, G03) : 2 axes

- Backlash compensation- Emergency stop / overtravel- Follow up- Least command increment : 0.001mm / 0.0001″- Least input increment : 0.001mm / 0.0001″- Machine lock all axes / Z axis- Mirror image Reverse axis movement

(setting screen and M - function)- Stored pitch error compensation Pitch error offset compensation for each axis- Stored stroke check 1 Overtravel controlled by software

IINNTTEERRPPOOLLAATTIIOONN && FFEEEEDD FFUUNNCCTTIIOONN- 2nd reference point return G30- Circular interpolation G02, G03- Dwell G04- Exact stop check G09, G61(mode)- Feed per minute mm / min- Feedrate override (10% increments) 0 - 200 %- Jog override (10% increments) 0 - 200 %- Linear interpolation G01- Manual handle feed(1 unit)- Manual handle feedrate 0.1/0.01/0.001mm- Override cancel M48 / M49- Positioning G00- Rapid traverse override F0 (fine feed), 25 / 50 / 100 %- Reference point return G27, G28, G29- Skip function G31- Helical interpolation- NANO AICC (AI Contour Control) 80 block preview- Thread cutting, synchronous cutting- Program restart- Automatic corner deceleration- Feedrate clamp by circular radius- Linear ACC/DEC before interpolation- Linear ACC/DEC after interpolation- Control axis detach- Rapid traverse bell-shaped acceleration/deceleration- Dual position feedback

SSPPIINNDDLLEE && MM--CCOODDEE FFUUNNCCTTIIOONN- M- code function M 3 digits- Spindle orientation- Spindle serial output- Spindle speed command S5 digits- Spindle speed override (10% increments) 10 - 150 %- Spindle output switching - Retraction for rigid tapping- Rigid tapping G84, G74

TTOOOOLL FFUUNNCCTTIIOONN- Cutter compensation C G40, G41, G42- Number of tool offsets 200 ea- Tool length compensation G43, G44, G49- Tool number command T3 digits- Tool life management Geometry / Wear and Length / Radius offset memory- Tool offset memory C

PPRROOGGRRAAMMMMIINNGG && EEDDIITTIINNGG FFUUNNCCTTIIOONN- Absolute / Incremental programming G90 / G91- Auto. Coordinate system setting- Background editing- Canned cycle G73, G74, G76, G80 - G89, G99- Circular interpolation by radius programming- Custom macro B- Custom size 512kb- Addition of custom macro common variables- Decimal point input- I / O interface RS - 232C- Inch / metric conversion G20 / G21- Label skip- Local / Machine coordinate system G52 / G53- Maximum commandable value ±99999.999mm (±9999.9999 inch)- No. of Registered programs 200 ea- Optional block skip- Optional stop M01- Part program storage 640 m

NC Unit Specifications (Fanuc 18i-MB)

23

Design and specifications are subject to change without prior notice. EU0805SPi-ser

Sales & Support Network

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Head Office : Doosan Tower 22nd FL., 18-12, Euljiro-6Ga, Jung-Gu, Seoul, Korea 100-730Tel : ++82-2-3398-8651 Fax : ++82-2-3398-8699 E-mail : [email protected]

Doosan Infracore America Corp.: 8 York Avenue, West Caldwell, NJ 07006, U.S.A.Tel : ++1-973-618-2500 Fax : ++1-973-618-2501

Doosan Infracore Germany GmbH : Hans-Böckler-Strasse 29, D-40764 Langenfeld-Fuhrkamp, Germany.Tel : ++49-2173-8509-10 Fax : ++49-2173-8509-60

China Representative Office : 9-101 Xinmao Building, 99 Tianzhou Road, Caohejing Hi-Tech Development Shanghai, China 200233 Tel : ++86-21-5445-1155 (812,815) Fax : ++86-21-64403389

http://domss.doosaninfracore.com

High Performance Horizontal Machining Center

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